Emission control and OBD SERVICE & INFOS TIPS I BRING YOU THE POWER OF KOLBENSCHMIDT, PIERBURG AND TRW ENGINE COMPONENTS! Motor Service Group. Quality and Service from a single source. The Motor Service Group is the sales organisation for the worldwide aftermarket activities of Kolbenschmidt Pierburg. It is one of the leading suppliers of engine components for the independent aftermarket including the premium brands KOLBENSCHMIDT, PIERBURG and TRW Engine Components. Our comprehensive product range allows our customers to procure engine components from a single source. As a problem solver for dealers and garages, Motor Service off ers extensive services and the technical expertise that you would expect from the subsidiary of one of the largest automotive suppliers. Kolbenschmidt Pierburg. Renowned supplier to the international automotive industry. As long-standing partners to the automotive industry, the companies in the Kolbenschmidt Pierburg Group develop innovative components and system solutions with acknowledged competence for air supply and emission control, for oil and water pumps, for pistons, engine blocks and engine bearings. The products comply with the high demands and quality standards of the automotive industry. Low emissions, reduced fuel consumption, reliability, quality and safety – these are the forces that drive innovation at Kolbenschmidt Pierburg. 2nd edition 01.2010 Liability Article-No. 50 003 960-02 All information in this brochure has been carefully researched and ISBN 978-3-86522-270-1 compiled. Nevertheless, it is possible that errors have occurred, information has been translated incorrectly, information is missing or Edited by: the details provided have changed in the intervening time. As a result, Motor Service, Technical Market Support we are unable to provide any guarantee nor to accept any legal liability for the accuracy, completeness, currency or quality of the information Layout and production: provided. We hereby waive all liability for any damages, whether direct Motor Service, Marketing or indirect in nature and whether tangible or intangible, resulting from Die Neckarprinzen GmbH, Heilbronn the use or misuse of information or from incomplete or incorrect information in this brochure, unless proven to be the result of This document must not be reprinted, duplicated deliberate intent or negligence on our part. or translated in full or in part without our prior written consent and without reference to the Likewise, we shall not be liable for damage arising because the engine source of the material. reconditioner or mechanic does not have the necessary technical expertise, the required knowledge of, or experience in repairs. All content including pictures and diagrams is subject to alteration. No liability accepted. The extent to which the technical methods and repair information described here will apply to future engine generations cannot be Published by: predicted and must be verifi ed in individual cases by the engineer © MS Motor Service International GmbH servicing an engine or the workshop operator. 2 | Emission control and OBD Table of contents Table of contents Page 1 | Introduction 4 2 | On-Board-Diagnosis 5 3 | Systems and diagnosis – general instructions 19 4 | Systems and diagnosis with PIERBURG products 22 5 | Further systems and diagnosis 53 6 | Basic principles 65 7 | Attachment 68 Emission control and OBD | 3 2 | On-Board-Diagnosis In this brochure we offer simple informa- OBD II and the European version, EOBD, In addition to information on the structure tion on the complex subject of “self diag- are discussed here. and functioning of the systems, possible nosis in motor vehicles”. Known as “On- This brochure is intended for use by auto- errors and the inter dependencies between Board-Diagnosis” (OBD), this self diagno- motive specialists. fault codes and causes are discussed. sis has become an internationally recog- It is intended to help you in your daily Furthermore we offer practical instructions nised term. It serves to monitor the run- work, especially in the error diagnosis of for diagnosing and correcting errors in ning of the engine and is used for emission automobiles with OBD systems. emissions-relevant components. control. Laws for the environment lar service checkups in the workshop, fault Our experience for you s the number of motor vehicles and amount codes and error rele vant data can be read PIERBURG is an active developer and manu- of traffic increases, the impact of exhaust out of the fault code memory. The fault code facturer of components, especial ly in the gas emissions on the environment has also memory is read out for the corresponding ve­­ field of emissions control. increased. Since 1968 toxic emissions have hic les for exhaust gas inspections (EGI). This Because all exhaust gas relevant compo- been restricted for motor vehicles in western way, errors that could cause damage to the nents are monitored by OBD, here we have industrialised nations. The United States engine or increased negative impact on the extensive experience in questions related to played a leading role in this legislation. environment can be detected early and rem- application and service. As the years went by, these legal limits for edied before damage occurs. By presenting this brochure it is our desire to toxic emissions have been lowered continu- share this experience with you. For this ously. To ensure compliance with these OBD = a solution to all problems? reason, in the description of systems and limits during daily operation, diagnostic sys- OBD does indeed detect a malfunctioning diagnostic instructions we concentrate on tems for monitoring exhaust gas relevant part or a function that is not working alto- PIERBURG products. systems and components (“On-Board-Diag- gether properly, but not always the actual Because it is only since 2003 that EOBD also nosis”), among other things, were required. cause of the failure or error. applies to passenger vehicles and light util- For this reason, all newer vehicles are This requires the expertise of a specialist ity vehicles with diesel engines, emphasis is equipped with On-Board diagnostic systems with knowledge of the system. placed on vehicles with petrol engines. that detect, record and display errors. In the event of a malfunction, or during regu- 4 | Emission control and OBD On-Board-Diagnosis | 2 2.1 California in the leadership role The EURO III emissions standard In the United States this problem was At the same time as the EURO III emissions 2.1 Development of On- recognised early and addressed by legisla- standard, the European version, “EOBD”, Board-Diagnosis (OBD, tion in 1984. With this legis lation, the On- was introduced in Europe as of January 1, OBD II and EOBD) Board-Diagnosis (OBD) was introduced for 2000. California from 1988 and for the entire It applies to passenger vehicles and light In conjunction with emission control, since USA from 1989. utility vehicles with petrol engines . 1970 the number of mechanical and elec- This was a simplified On-Board As of 2003 it also applies to passenger tric components in the engine environment diagnostic system. vehicles and light utility vehicles with has increased. It required the registering, recording and diesel engines. These new components have made it incre- displaying of errors in exhaust gas The EOBD essentially corresponds to the asingly difficult for workshops to diagnose relevant components of the vehicle. In this American OBD II. It has, however, been errors in cases of malfunctions. first version only components directly “eased” in some points. To solve these problems, at the end of the associated with the control unit were • A leak test of the fuel system is not seventies, the first, still very elementary, monitored. Errors were indicated by a mal- required. vehicle integrated diagnostic systems function indicator lamp. Readings were • For exhaust gas recirculation, secon dary were introduced. taken by interpreting blinking codes. air and fuel tank ventilation, only the This was made possible by the develop- functioning and the electric connections ment of increasingly more proficient elect- OBD II of the individual compo nents are tested. ronic control units. At the same time, As of January 1, 1996, OBD II was required A test of the effectiveness of these sys- increasing numbers of new or further for passenger cars and light utility vehic- tems is not required by the EOBD. developed sensors and actuators were les in the United States. As a result a diag- There are, however, vehicle manufacturers being used. nostic system with considerably expanded that comply with the “OBD II” standard This also required an increase in the functions was introduced. In addition to worldwide. number of on-board power supply net- exhaust gas relevant components, further works and plug-in connections. systems and functions were now monito- But another consequence of this develop- red during operation. Malfunctions and ment was that, in the event of a malfunc- deviations were entered in a “nonvolatile” tion or breakdown, uncertainty frequently (permanent) memory. Furthermore, as a reigned in diagnosing the error. help in error diagnosis, operating condi- In order to improve the situation, since tions that were present when an error about 1984, increasing numbers of vehic- occurred were registered and recorded. les were being equipped with improved An additional, essential improvement was systems for error detection, with fault the establishment of stan dardised inter- code memories and self diagnosis. faces, data transfer protocols, scan tools, There were very different philosophies diagnostic sockets and fault codes. This regarding the scope and use of these On- made it possible for the fault code memory Board diagnostic systems. The result was to be read using conventional OBD compa- a multitude of system va riants, interfaces, tible instruments. adapters, data scan tools and fault codes. Furthermore it was determined that the As a result, in many cases an error diagno- vehicle manufacturer should make the sis was possible only in the respective data necessary for service available to all contrac ted workshops.